By Manjunath N. Reddy, Founder and Managing Director, DhaSh Group of Companies
As India accelerates its renewable energy ambitions, the focus on solar balance-of-system (BoS) components is intensifying. While modules and inverters dominate industry conversations, the long-term performance, safety and bankability of solar projects depend heavily on the reliability of components that connect, protect and transmit power. Solar cables, connectors and junction boxes form the electrical backbone of photovoltaic (PV) systems, and their evolution is closely linked to the scale, efficiency and operating environments of modern solar installations.
This article examines key technology trends shaping these components, recent advancements and their adoption in the Indian market, along with a broader look at domestic manufacturing, policy considerations and market outlook…
Expanding role of junction boxes in high-power solar modules
Solar modules have undergone a significant transformation in recent years. Larger wafer sizes, higher cell efficiencies and increased module power ratings have driven a shift towards large-format and high-current modules, including advanced configurations such as glass-to-glass (G2G) modules. This evolution has directly impacted the design and function of junction boxes.
Traditionally viewed as a passive connection point, the junction box is now a critical component for both safety and performance. Higher module currents demand junction boxes with improved thermal management, enhanced electrical insulation and robust internal layouts to prevent overheating and potential failure.
A key trend in this area is the development of higher-rated current junction boxes, such as DhaSh TRIO Max 2,000V DC, that can safely support increased electrical loads without compromising safety or longevity. The internal architecture of such modern 2,000V DC junction boxes is being redesigned with higher creepage/clearance distances, improved contact materials and optimised layouts, enabling them to achieve improved dielectric strength without tracking down and continuing to possess superior heat dissipation abilities under elevated ambient temperature and continuous rated current applications.
As G2G modules gain traction, particularly in utility-scale and demanding environments, the junction box must also support improved ingress protection and long-term sealing performance, as moisture and temperature variations can directly affect system reliability over a project’s 30-year lifespan.
Diode safety and the growing importance of protection mechanisms
Diodes play a critical role within junction boxes by providing continuous forward bias/bypass mode operation under shaded or partially shaded conditions and protecting solar cells from hotspot formation under such partial shading or inter-module Imp (maximum power current) mismatch conditions. As module power classes increase, diode safety factors and thermal performance are becoming more important.
Recent advancements focus on higher current-rated bypass diodes. Improved thermal dissipation mechanisms result in controlled junction temperature values. These measures prevent thermal runaway events during the module’s transition from cloudy state to sunny state or other similar events encouraging thermal runaway scenarios.
These developments help ensure that diodes can operate reliably under higher electrical and thermal stress, reducing the risk of premature failures. The industry is increasingly recognising that a diode’s reliability is directly linked to system uptime, warranty performance and long-term return on investment for project developers.
Moving towards 2,000 V DC systems for improved project economics
One of the most significant shifts in solar BoS technology is the gradual adoption of 2,000 V DC-rated junction boxes and connectors. While 1,500 V DC systems are currently the industry standard in many large-scale projects, higher voltage architectures are gaining interest due to their potential to reduce system costs.
Higher DC voltage systems can lower cable and conductor requirements, reduce overall system losses, enable longer string lengths, improve inverter utilisation, and enhance the dielectric strength of PV modules and components, reducing the risk of tracking events or insulation failure.
These factors contribute to improved levellised cost of energy and overall project economics. However, the transition to 2,000 V DC places greater demands on the quality, insulation performance and safety design of junction boxes, connectors and cables.
As a result, manufacturers and developers are paying closer attention to material selection, testing standards and long-term reliability validation.
Advances in solar cables and the role of E-beam technology
Solar cables operate in some of the most challenging environments in the electrical ecosystem. Prolonged exposure to ultraviolet radiation, temperature extremes, moisture and mechanical stress makes insulation performance a defining factor in long-term system reliability.
One of the key technological advancements in this area is the use of electron beam (E-beam) cross-linking technology. E-beam processing enhances the molecular structure of cable insulation, resulting in improved thermal stability, higher resistance to ageing and degradation, enhanced mechanical strength and better performance under continuous outdoor exposure.
These characteristics make E-beam cross-linked cables particularly suited for large-scale solar installations designed for multi-decade operation. As developers and financiers increasingly focus on lifecycle performance rather than just upfront costs, the adoption of advanced cable technologies is gaining momentum in the Indian market.
Connectors and DC interconnection systems
Solar connectors, while relatively small in size, have a significant impact on system performance and safety. Poor quality or mismatched connectors can lead to increased contact resistance, localised heating and, in extreme cases, electrical arcing and burn-out failure of connectors.
The industry trend is moving towards precision-engineered connectors that ensure consistent crimped-contact and mating length, optimal electrical resistance in the mated condition, high ingress protection, and long-term mechanical stability.
With the growth of high-power modules and higher system voltages, connectors must also meet stricter insulation and thermal performance requirements. Standardisation and compatibility are becoming increasingly important, especially in large utility-scale projects where thousands of connection points must perform reliably over decades.
Demand for corrosion-resistant materials
India’s solar landscape is expanding beyond traditional ground-mounted and rooftop systems. Floating solar projects and coastal installations are emerging as important segments, particularly in water-scarce and land-constrained regions. These environments introduce new challenges for BoS components, including high humidity, saline conditions, increased corrosion risk and mechanical stress from wind and water movement.
As a result, there is a growing demand for corrosion-resistant materials and composite structural solutions, including composite frames and advanced enclosures. These materials offer improved resistance to environmental degradation while maintaining structural integrity and electrical safety over long operating periods.
Domestic manufacturing and backward integration
India’s push for self-reliance in renewable energy manufacturing has placed greater emphasis on the domestic production of BoS components. Junction boxes, connectors, cables and interconnection materials are increasingly being manufactured within the country, supported by policy initiatives and industry investment.
Backward integration into areas such as polymer compounding, tooling and automation is helping manufacturers improve quality consistency, supply chain reliability, cost competitiveness and speed of innovation. This shift is strengthening India’s position not only as a large solar market but also as a growing hub for solar component manufacturing.
Policy considerations and efficiency measures
From a policy perspective, the continued development of standards and certification frameworks is essential to ensure safety and performance across the rapidly expanding solar sector. Areas that merit further attention include standardisation of high voltage DC components, enhanced testing protocols for long-term outdoor performance and clear guidelines for floating and coastal solar installations. In parallel, efficiency improvement measures at the manufacturing and project level, such as energy audits, material optimisation and waste reduction, are helping align solar BoS development with broader sustainability goals.
Market outlook
The Indian solar market is expected to continue its strong growth trajectory, driven by national energy targets, grid expansion and declining system costs. As projects become larger and more technologically advanced, the role of BoS components will become even more critical.
Future demand is likely to be shaped by higher voltage and high current architectures, larger and more efficient module formats, expansion into diverse operating environments and a greater focus on lifecycle performance and reliability.
In this context, solar cables, connectors and junction boxes will increasingly be viewed not as commoditised parts, but as strategic components that directly influence project performance, safety and financial outcomes.
The evolution of solar BoS technology in India reflects the broader maturation of the renewable energy sector. Advancements in junction boxes, diode safety, E-beam cross-linked cables, high voltage connectors and corrosion-resistant materials are enabling the industry to scale while maintaining safety and performance standards.
As the market moves towards higher power, higher voltage and more diverse deployment environments, continued innovation in these critical components will play a central role in supporting India’s transition toward a reliable, efficient and self-reliant solar energy ecosystem.
